Fundamental analysis of EDM die-sinking applying different tungsten carbide
Final Report Abstract
Due to the poor machinability of tungsten carbide (WC) materials, the use of WC-electrodes in electrical discharge machining (EDM) is strongly limited, although tungsten carbides show advantageous properties for EDM and are already used as tube electrodes in EDM drilling. As part of the research project, various tungsten carbides with cobalt binder (WC-Co) were classified according to their material properties and the influence of these material properties on EDM process behaviour was determined. Furthermore, the influence of EDM process parameters on EDM sinking with tungsten carbide electrodes was determined in both macro- and micro-machining. Based on the extensive sinking tests, regression equations were developed, which formed the basis for determining suitable parameter sets for macro- and micro-machining. Furthermore, a comparison was made between tungsten carbide electrodes and electrodes made of graphite as well as electrolytic copper, which are commonly used in die-sinking EDM. The results of these investigations were used to determine dedicated areas of application for WC-Co electrodes in electrical discharge machining. Particularly in micro-machining, a very advantageous tool wear behaviour of the carbide electrodes could be demonstrated, whereby significant improvements in the achievable shape accuracies in the electrical discharge machining of microstructures are possible compared to the current state of the research.
Publications
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Fundamental research of applying tungsten carbide-cobalt as tool electrode material for sinking EDM. Procedia CIRP, 95, 466-470.
Uhlmann, Eckart; Polte, Mitchel; Bolz, Robert & Börnstein, Julian
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Novel Advances in Machine Tools, Tool Electrodes and Processes for High-Performance and High-Precision EDM. Procedia CIRP, 113, 611-635.
Uhlmann, Eckart; Polte, Mitchel & Yabroudi, Sami
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Validation of different tungsten carbide-cobalt grades as tool electrode material for sinking EDM. Procedia CIRP, 113, 125-130.
Uhlmann, Eckart; Bolz, Robert; Polte, Mitchel & Börnstein, Julian
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Die-sinking electrical discharge machining of nickel-based alloy with different tungsten carbide-cobalt grades, Vortrag am 9.07.2023, FEMS EUROMAT 2023, Frankfurt/Main.
Uhlmann, E.; Bolz, R.; Polte, M. & Hein
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Echtzeit-Energieüberwachung in der Funkenerosion/Real-time energy monitoring in electrical discharge machining – Advanced software practices for signal analysis and classification. Wt Werkstattstechnik Online, 113(07–08), 304–310.
Uhlmann, Eckart; Polte, Mitchel; Yabroudi, Sami; Thißen, Kai & Penske, Wilhelm
